Textured cleansing article

ABSTRACT

The present invention relates to dual textured treatment cleansing articles comprising first and second outer members forming first and second sides of the article. The first and second sides are both textured, although preferably the sides have different textures to provide the user with differing degrees of cleaning in a single cleansing article. For example, in one embodiment, the first side has coefficient of friction greater than 0.50, such as from 0.50 to about 0.75 and more preferably from about 0.55 to about 0.65, and the second side has coefficient of friction less than 0.50, such as from about 0.30 to 0.50 and more preferably from about 0.35 to about 0.45

BACKGROUND OF THE DISCLOSURE

It is well known in the art to deliver cleansing products to a user with a single disposable pad. While the construction of such disposable cleansing articles varies widely, it is common for cleansing articles to have a single layer having a single textured surface. For example, U.S. Pat. Nos. 3,537,121 and 3,910,284 disclose single layer nonwoven cleansing articles that clean without scratching or abrading the target surface. In other instances cleansing articles having two or more layers have been developed to improve the durability or hand feel of the pad. In certain instances the use of multiple layers may also enable a pad to have two wiping surfaces with differing textures. Too often however the texture provided by the different outer layers of the pad have significantly differing texture, such as one surface that is substantially smooth for polishing, and the like, and the other having a large degree of texture for scrubbing, and the like. Moreover, the layers comprise similar webs where one web simply has a texturing agent disposed on its surface. In this manner the texture of the pad may differ between the first and second sides, but the permeability of the layers is substantially similar.

Thus, there remains a need in the art for a cleansing article, such as a wiping pad, having two outer layers constructed from different materials having different permeabilities where both sides have some degree of three-dimensional topography, but provide the user with two distinct textured wiping surfaces.

SUMMARY OF THE DISCLOSURE

The present cleansing article overcomes many of the limitations of the prior art by providing a cleansing article having two distinct textures on its first and second sides. The dual textured cleansing articles of the instant invention allow for one side to be used for scrubbing and the other for gentle cleansing. Additionally, the more highly textured side of the wipe comprises raised elements that tend to concentrate removed soil and dirt on the raised areas, thereby enhancing the user's perception of cleansing efficacy.

In addition to having different textures the two sides of the cleansing article may have different permeabilities. One advantage of providing each side of the cleansing article with different permeabilities is to control the deposition of cleansing formulations on the surface of the article. Thus, in certain embodiments the invention provides a cleansing article with dual texture and permeability where the article comprises first and second members, the members have different permeabilities and outer surfaces with different textures.

In other embodiments the present invention provides a first member comprising a nonwoven web having a first and a second side and a plurality of protuberances disposed on the first side thereof, wherein the protuberances have an average height greater than about 250 μm; a second member comprising a nonwoven web having a first and a second side and a plurality of projections substantially surrounded by land areas disposed on the first side, the land areas lying in a first plane and the projections terminating at distal ends lying in a second plane wherein the average distance between the first and the second planes is greater than about 0.5 mm. In certain embodiments a core may be disposed between the first and second layers and the first layer, core and second layer may be bound together.

In still other embodiments the present invention provides a cleansing article comprising: a first member comprising a nonwoven web having a first and a second side and a plurality of polymeric protuberance disposed on the first side thereof, the first side forming the first outer surface of the cleansing article; a second member comprising a nonwoven web having a first and a second side, the first side having a plurality of projections substantially surrounded by a landing, the land areas lying in a first plane and the projections terminating at distal ends lying in a second plane, the first and second planes spaced apart a vertical distance from about 0.5 to about 2.0 mm, wherein the first side forms the second outer surface of the cleansing article; and a core.

In yet other embodiments the present invention provides a textured cleansing article comprising: a first member comprising a nonwoven web having a first and a second side, the web having a permeability of 500 cfm or greater and the first side forming the first outer surface of the cleansing article, which has a coefficient of friction greater than 0.50; a second member comprising a nonwoven web having a first and a second side, the web having a permeability less than 500 cfm and the first side forming the second outer surface of the cleansing article, which has a coefficient of friction less than 0.50.

In still other embodiments the present invention provides a textured cleansing article comprising: a first member comprising a nonwoven web having an outer and an inner surface, a plurality of non-hollow protuberances disposed on the outer surface, the first member having a permeability greater than 500 cfm and a coefficient of friction from about 0.55 to about 0.60; a second member comprising a fluid-entangled laminate web having an outer and an inner surface, the outer surface of the web having a plurality of hollow projections, the second member having a permeability less than 500 cfm and a coefficient of friction from about 0.35 to about 0.45; and a core disposed between the first and the second members.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an exploded view of a textured cleansing article according to one embodiment of the present invention;

FIG. 2 is a top plane view of one surface of a textured cleansing article according to one embodiment of the present invention;

FIG. 3 is a top plane view of one surface of a textured cleansing article according to one embodiment of the present invention;

FIG. 4 is a cross-sectional view of a textured cleansing article according to one embodiment of the present invention through the line X-X of FIG. 3;

FIG. 5 is a top plane view of one surface of a textured cleansing article illustrating one exemplary pattern of protuberances disposed on one surface of the article; and

FIG. 6 is a top plane view of one surface of a textured cleansing article illustrating one exemplary pattern of protuberances disposed on one surface of the article.

DEFINITIONS

As used herein the term “nonwoven web” generally refers to an article or sheet having a structure of individual fiber or fibers, which are interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven fabrics or webs have been formed from many processes such as for example, meltblowing processes, air-laying processes, and bonded carded web processes.

As used herein the terms “meltblowing” and “meltblown process” generally refer to a method for forming a nonwoven fibrous web by extruding a molten fiber-forming material through a plurality of orifices in a die to form fibers while contacting the fibers with air or other attenuating fluid to attenuate the fiber into fibers, and thereafter collecting the attenuated fibers. Arm exemplary meltblowing process is taught in, for example, U.S. Pat. No. 6,607,624.

As used herein the terms “spun-bonding” and “spun bond process” generally refer to a method for forming a nonwoven fibrous web by extruding molten fiber-forming material as continuous or semi-continuous fibers from a plurality of fine capillaries of a spinneret, and thereafter collecting the attenuated fibers. An exemplary spun-bonding process is disclosed in, for example, U.S. Pat. No. 3,802,817.

As used herein the terms “spun bond fibers” and “spun-bonded fibers” generally refer to fibers made using spun-bonding or a spun bond process. Such fibers are generally continuous fibers and are entangled or point bonded sufficiently to form a cohesive nonwoven fibrous web such that it is usually not possible to remove one complete spun bond fiber from a mass of such fibers.

As used herein the term “air-laying” generally refers to a process by which a nonwoven fibrous web layer can be formed. In the air-laying process, bundles of small fibers having typical lengths ranging from about 3 to about 52 millimeters (mm) are separated and entrained in an air supply and then deposited onto a forming screen, usually with the assistance of a vacuum supply. The randomly oriented fibers may then be bonded to one another using, for example, thermal point bonding, autogenous bonding, hot air bonding, needle punching, calendering, a spray adhesive, and the like. An exemplary air-laying process is taught in, for example, U.S. Pat. No. 4,640,810.

As used herein the term “fluid-entangled laminate web” generally refers to a multi-layered nonwoven fibrous web comprising a support layer and a nonwoven projection web which are entangled using a fluid. An exemplary fluid-entangled laminate web and processes for forming the same are disclosed in, for example, U.S. Pat. No. 9,327,473.

As used herein, the term “fluid entangling” and “fluid-entangled” generally refers to a formation process for further increasing the degree of fiber entanglement within a given fibrous nonwoven web or between fibrous nonwoven webs and other materials so as to make the separation of the individual fibers and/or the layers more difficult as a result of the entanglement.

As used herein the term “co-form” or a “co-forming process” generally refer a process in which at least one fiber layer is formed substantially simultaneously with or in-line with formation of at least one different fiber layer. Webs produced by a co-forming process are generally referred to as “co-formed webs.”

As used herein the term “non-hollow” with particular reference to projections extending from a major surface of a nonwoven fibrous web means that the projections do not contain an internal cavity or void region other than the microscopic voids (i.e. void volume) between randomly oriented discrete fibers.

As used herein the term “hollow” with particular reference to projections extending from a major surface of a nonwoven fibrous web means that the projections contain an internal cavity or void region.

As used herein the term “layer” generally refers to a single stratum formed between two major surfaces. A layer may exist internally within a single web, e.g., a single stratum formed with multiple strata in a single web having first and second major surfaces defining the thickness of the web. A layer may also exist in a composite article comprising multiple webs, e.g., a single stratum in a first web having first and second major surfaces defining the thickness of the web, when that web is overlaid or underlaid by a second web having first and second major surfaces defining the thickness of the second web, in which case each of the first and second webs forms at least one layer. In addition, layers may simultaneously exist within a single web and between that web and one or more other webs, each web forming a layer.

As used herein the term “adjoining” with particular reference to various layers of the cleansing article of the present invention generally means a given layer (a first member) joined with or attached to another given layer (a second member), in a position wherein the first and second members are either next to (i.e., adjacent to) and directly contacting each other, or contiguous with each other but not in direct contact (i.e., there are one or more additional layers intervening between the first and second members).

As used herein the term “coefficient of friction” (COF) refers to the MIU value for a given sample as determined using a KES Surface Tester, as described in the Test Methods section below. Typically coefficient of friction is measured along one direction of a product. Where a product has both a machine and a cross-machine direction, coefficient of friction is measured in the machine direction (MD). Higher values of MIU indicate more drag on the sample surface. Coefficient of friction is generally referred to herein without reference to units. MIU is defined by:

MIU(μ)=1/X∫ ₀ ^(x) μdx

where μ=friction force divided by compression force μ=mean value of μ x=displacement of the probe on the surface of specimen, cm X=maximum travel used in the calculation, 2 cm.

As used herein the term “surface smoothness” refers to the mean deviation of MIU (MMD) where higher values of MMD indicate more variation or less uniformity on the sample surface. The MMD value for a given sample as determined using a KES Surface Tester, as described in the Test Methods section below. Typically smoothness is measured along one direction of a product. Where a product has both a machine and a cross-machine direction, smoothness is measured in the machine direction (MD). Higher values of MMD indicate more drag on the sample surface. Surface smoothness is generally referred to herein without reference to units. MMD is defined as:

MMD=1/X∫ ₀ ^(x) |μ−μ|dx

where μ=friction force divided by compression force μ=mean value of μ x=displacement of the probe on the surface of specimen, cm X=maximum travel used in the calculation, 2 cm.

As used herein the term “permeability” generally refers to the air permeability of a given layer of the cleansing article measured as described in the Test Methods section below.

DETAILED DESCRIPTION OF THE DISCLOSURE

Generally, the present invention provides a textured cleansing article for use in cleaning any manner of body surfaces, and particularly a user's face. The textured cleansing article comprises first and second outer members forming first and second sides of the article. The first and second sides are both textured, although preferably the sides have different textures to provide the user with differing degrees of cleaning in a single cleansing article. For example, in one embodiment, the first side has a coefficient of friction greater than 0.50, more preferably greater than about 0.55, such as from about 0.55 to about 1.00 and more preferably from about 0.55 to about 0.75, and the second side has a coefficient of friction less than 0.50, such as from about 0.30 to 0.50 and more preferably from about 0.35 to about 0.45.

One embodiment of the instant cleansing article is illustrated in FIG. 1, which illustrates an article 10 comprising three members, also referred to herein as layers, such as a first outer member 14, a core 16 and a second outer member 18. Generally each member, or layer, 14, 16, 18 is formed from a different material so as to provide the article 10 with first and second sides 24, 26 with different properties such as texture or permeability. Each of the layers have a periphery along the outer edges of the material circumscribing the piece of material comprising the layer.

Turning now to FIG. 2, one embodiment of a first outer member 14 of the article 10 is illustrated. The first outer member may be made from any suitable synthetic or natural material so as to provide a layer that is compliant and compressible to the touch. The first outer member may be wet laid, air laid, or made by other methods. Numerous materials are suitable for use in the first outer member and include, but are not limited to, knit or woven fabrics, nonwoven fabrics, and porous open cell foams. Suitable polymers include, but are not limited to, polyolefins (e.g. polyethylene and polypropylene), polyesters (e.g. polyethylene terephthalate), polyamides (e.g. nylon), viscose, and mixtures thereof. Desirably, the first outer member comprises a fibrous layer having a substantially uniform composition and is laid in such a manner so as to provide a substantially uniform outer surface. Non-limiting examples of suitable natural materials and derivatives thereof include woven and nonwoven materials made of fibers such as cotton, wood pulp, viscose, or mixtures thereof. Exemplary nonwoven fabrics include, but are not limited to, spunlace (hydroentangled materials), spunbond, meltblown, and bonded-carded webs.

In certain embodiments the first outer layer comprises a nonwoven web having a basis weight from about 10 to about 200 grams per square meter (gsm), such as from about 30 to about 150 gsm, and still more preferably from about 50 to about 100 gsm. By way of a specific example, the first outer member may comprise a bonded carded web having a basis weight from about 30 to about 100 gsm. The foregoing webs preferably have a permeability of 500 cfm or greater, such as from 500 to about 600 cfm and more preferably from 500 to about 550 cfm.

To provide an article having differing textures on its first and second sides the instant article generally comprises a first and second outer members having different construction. For example, the first outer member 14 may be manufactured to have a distinctly different, e.g. rougher, hand-feel relative to that of the second outer member 18. More specifically, the first outer member may be made from synthetic or natural material or blend thereof that is sufficiently coarser and/or highly textured (uneven) than the material used to form the second outer layer so as to provide a greater mechanical cleaning action against the skin. In other instances the enhanced texture of the first outer member can be achieved by the use of materials including and/or having thereon the following: bound particles, formed and/or deposited polymeric nodules, fabrics or mesh having large diameter fibers or yarns, bonded fiber tufts, and so forth. By way of non-limiting example, various suitable materials for use in the first outer member are described in U.S. Pat. Nos. 4,659,609, 4,769,022, 5,067,400 and 6,713,156.

In certain embodiments, the first outer member may comprise a fibrous material having protuberances, also referred to herein as nodules or protrusions, exposed on the outer surface thereof. The size and/or frequency of the protuberances may be varied to impart the desired hand-feel. The protuberances preferably have a diameter of at least about 100 μm and in further aspects such protuberances may have an average diameter from about 100 to about 2,000 μm and, more desirably, average diameters from about 200 μm to about 1,000 μm. In a particularly preferred embodiment the protuberances have a diameter of at least about 100 μm and are non-hollow.

The protuberances may be formed by depositing the same upon a preformed web. The protuberances may be applied randomly across the surface of the web or in one or more patterns as desired such as through the use of rotogravure or gravure printing (direct or indirect), flexographic printing, screen printing, stencil application and so forth. Suitable materials for forming protuberances include, but are not limited to, polyolefins, ethylene vinyl acetate, thermoplastic elastomers, microcrystalline waxes, and natural or synthetic resins. Materials commonly utilized as hot-melt adhesives, and in particular oil-resistant hot-melt adhesives such as described in US Patent Publication No. 2007/142801, may be used to form deposited polymeric protuberances.

In certain embodiments, it may be desirable that the polymeric material forming the protuberances have a hardness of at least 65, and still more desirably at least about 70, and still more desirably at least about 80. In certain embodiments, the polymeric material forming the protuberances may have a hardness of between 65 and 100 and, in still further embodiments, may have a hardness between about 70 and about 90. As used herein, hardness of the polymeric material is determined in accordance with ASTM D2204 (Type D). In still other embodiments, the polymeric material forming the protuberances, including nodules and/or fibers, may desirably have a flexural modulus of about 500 MPa and still more desirably may have a flexural modulus of about 800 MPa or greater. Flexural modulus is determined in accordance with ASTM D790. In an alternative embodiment, the polymeric material may have both the flexural modulus and hardness properties described herein above.

In certain embodiments the protuberances have a spherical or a partially spherical shape and have an average diameter, generally measured at the point the protuberance contacts the web, of at least about 500 μm and more preferably at least about 700 μm and still more preferably at least about 1,000 μm, such as from about 500 to about 2,000 μm and more desirably from about 700 to about 1,500 μm.

The protuberances generally extend from the surface plane of the first side in the z-direction providing the protuberances with a height. In certain preferred embodiments the protuberances comprise a polymeric material printed onto a nonwoven web where the protuberances have an average height greater than about 150 μm, more preferably greater than about 250 μm, and still more preferably greater than about 400 μm, such as from about 150 to about 1,000 μm and more preferably from about 300 to about 650 μm. In certain preferred embodiments the height of the protuberances is relatively uniform such that the standard deviation of height is less than about ±50 μm and more preferably less than about ±25 μm.

In a particularly preferred embodiment the protuberances are spherical or partially spherical and have a volume greater than about 0.50 mm³ and more preferably greater than about 0.55 mm³ and still more preferably greater than about 0.60 mm³, such as from about 0.50 to about 0.75 mm³ and more preferably from about 0.55 to about 0.70 mm³. In other embodiments the protuberances have a spherical or a partially spherical shape, a height greater than about 500 μm, such as from about 500 to about 1,000 μm, and a volume greater than about 0.50 mm³ such as from about 0.50 to about 0.75 mm³.

The protuberances may be applied to the first outer layer in a random or non-random pattern. In a preferred embodiment the protuberances are applied to the first outer layer in a non-random pattern and cover at least about 5.0 percent of the surface area of the outer layer, such as from about 5.0 to about 15.0 percent. In other embodiments the protuberances may cover at least about 7.0 percent of the surface of the first outer layer, and still more preferably at least about 9.0 percent, such as from about 7.0 to about 13.0 percent. In other embodiments the number of protuberances per unit area of the first outer layer is generally greater than about 100,000 protuberances/m² and still more preferably greater than about 120,000 protuberances/m², such as from about 100,000 to about 200,000 protuberances/m² and more preferably from about 120,000 to about 170,000 protuberances/m².

The protuberances may be applied in any number of different non-random patterns including, for example, the non-random patterns illustrated in FIGS. 5 and 6. The pattern is generally formed by protuberances 30 printed on the first outer member 14 which forms first side 24 of the article 10. The article 10 may have a bonded edge 22 adjacent to its outer peripheral edge 20, which may lend aesthetics to the article 10, but generally does not form part of the overall pattern.

In other embodiments, texture may be imparted to the first outer member by applying particles to the precursor web used to form the first outer member. The particles may be held in position on the fibers by use of an adhesive, binder or other material. The binder material and associated particulate material may be applied to the web either across substantially the entire outer surface or, in other embodiments, in one or more desired patterns. Methods of applying the binder and associated particulate material include spraying, dip and squeeze, foam treating, rotogravure or gravure printing (direct or indirect), flexographic printing, screen printing and so forth. Alternatively, fibers may be formed with the particulate material contained therein or, in the case of thermoplastic fibers, the fibrous web containing the particles may be heated so as to fixedly embed the particles in the fibers while in a semi-molten state.

Particles suitable for use in adhering to the outer portion of the precursor web used to form the first outer member can be derived from a wide variety of materials including those derived from inorganic, organic, natural, and synthetic sources. By way of non-limiting example, suitable particles include: seeds and powders thereof (e.g. Kiwi, cranberry, sunflower, raspberry, jojoba, etc.), botanical shell/husk powders (e.g. almond, coconut, pecan, walnut, wheat, etc.), oyster shell powder, jojoba esters, polymeric beads or powders (e.g. polybutylene, polyethylene, polyisobutylene, polymethylstyrene, polypropylene, polystyrene, polyurethane, nylon, polytetrafluoroethylene, etc.), microcrystalline or synthetic wax, metal oxides (e.g. aluminum, tin, titanium, etc.), silicates (e.g. aluminum, zirconium, etc.), chalk, chitin, clay, microcrystalline cellulose, perlite, sericite, silica, talc and so forth.

In a further particular embodiment, the first outer member may comprise a web including fibers or yarns having a relatively coarse texture and/or having an average diameter greater than 75 μm and more desirably may have diameters in excess of about 100 μm. In a further aspect the filaments and/or yarns may have diameters between about 75 μm and about 1,000 μm or in further aspects between about 100 μm and about 500 μm. Suitable polymers for forming the large fibers and/or yarns include, but are not limited to, polyolefins (e.g. polyethylene and polypropylene), polyesters (e.g. polyethylene terephthalate), polyamides (e.g. nylon), and combinations thereof. A specific example of material suitable for use in the first outer member include a web woven from filament bundles or yarns ranging in size between about 200-800 μm wherein the (i) the first filament bundle comprises individual nylon filaments having an average fiber size of approximately 60 μm and (ii) the second filament bundle comprises individual polyethylene terephthalate filaments having an average fiber size of approximately 20 μm. In certain embodiments, larger and/or abrasive staple length fibers may be used in the formation of the web or, in the alternative, may be integrated into the outer surface of the web such as by needling and/or entangling.

With reference to FIG. 2, one embodiment of a first outer member 14 of the article 10 is illustrated. The first outer member 14 may be formed from a nonwoven web, or the like. A plurality of polymeric protuberances 30 are disposed on the outer surface the first outer member 14 to provide the first side 24 of the article 10 with texture. Generally the protuberances are raised above the outer surface of the nonwoven web and together form the first surface of the article.

Opposite the first side 24 is a second side 26 of the article 10, which is illustrated in FIG. 3. The second side 26 is formed by a second outer member 18. The second outer member may be wet laid, air laid, or made by other methods. Numerous materials are suitable for use in the second outer member and include, but are not limited to, knit or woven fabrics, nonwoven fabrics, and porous open cell foams. Suitable polymers include, but are not limited to, polyolefins (e.g. polyethylene and polypropylene), polyesters (e.g. polyethylene terephthalate), polyamides (e.g. nylon), viscose, and mixtures thereof. Non-limiting examples of suitable natural materials and derivatives thereof include woven and nonwoven materials made of fibers such as cotton, wood pulp, viscose or mixtures thereof. Exemplary nonwoven fabrics include, but are not limited to, spunlace (hydroentangled materials), spunbond, meltblown, and bonded-carded webs.

In certain embodiments, the second outer member may comprise a fibrous material such as a nonwoven web, which in certain instances may comprise a laminate of two or more webs. For example, the second outer member may comprise a multilayered laminated web comprising spunbonded/meltblown/spunbonded laminate, a spunbonded/meltblown laminate, and the like.

Preferably the outer surface of the second outer member has a three dimensional shape to provide a texturized surface. A texturized surface is particularly useful when the cleansing article is used to scrub or clean surfaces, such as the skin. In one embodiment the second outer member comprises a single-ply nonwoven web, the second outer member having a top and a bottom surface where the top surface is texturized. The manner in which a texturized surface is formed on a nonwoven web for use on the second outer member can vary depending upon the particular application of the desired result. For example, the precursor web may be embossed to provide a texturized surface. In another embodiment the web may be matte finished to provide a texture. In yet other embodiments a texturized surface may be imparted by thermally point unbonding a nonwoven web to form a plurality of tufts. As used herein, a substrate that has been “thermally point unbonded” refers to a substrate that includes raised unbonded areas or lightly bonded areas that are surrounded by bonded regions. For example, bumps or tufts are the unbonded or lightly bonded areas that form raised projections off the surface of the nonwoven web to provide the necessary texture. In still other embodiments the web may be fluid-entangled to form projections extending outwardly and away from the top surface of the web, such as described in U.S. Pat. No. 9,327,473.

Generally the means of texturizing the surface of the second outer member does not involve the deposition of material onto the surface of the web. Thus, in one preferred embodiment, the first and second outer members differ in the manner in which their outer surfaces are texturized. For example, the first outer member may be texturized by depositing a polymeric material on its outer surface to form protuberances while the second outer member may be texturized by mechanically treating the precursor web such as by embossing or fluid-entanglement to form projections.

In a particularly preferred embodiment the second outer member comprises a fluid-entangled laminate web with projections extending outwardly and away from at least one intended external surface of the laminate. Generally the fluid-entangled laminate web comprises a support layer and a fibrous nonwoven projection web where the fibers of the projection web cross the interface between the layers and are entangled with and engage the support layer so as to form the laminate. The basis weights for the fluid-entangled laminate web may vary depending on the end-use applications outlined herein, but generally may range from about 50 to about 200 gsm, though basis weights outside this range may be used depending upon the particular end-use application.

While the projections can be filled with fibers from the projection web and/or the support layer it is generally desirable for the projections to be generally hollow. The hollow projections desirably have closed ends which are devoid of holes or apertures. Such holes or apertures are to be distinguished from the normal interstitial fiber-to-fiber spacing commonly found in fibrous nonwoven webs. In some applications, however, it may be desirable to increase the pressure and/or dwell time of the impinging fluid jets in the entangling process as described below to create one or more holes or apertures (not shown) in one or more of the hollow projections. Such apertures may be formed in the ends or side walls of the projections as well as in both the ends and side walls of the projections.

The shape of the hollow projections may be, for example, round, oval, square, rectangular, triangular or diamond-shaped. In one preferred embodiment, the hollow projections may be round when viewed from above with somewhat domed or curved tops or ends such as seen when viewed in the cross-section. Both the width and depth of the hollow projections can be varied as can be the spacing and pattern of the projections. Further, various shapes, sizes and spacing of the projections can be utilized in the same web. In one embodiment, the projections can have a height from about 0.5 to about 5.0 mm, such as from about 0.5 to about 2.0 mm and more preferably from about 0.75 to about 1.5 mm.

The hollow projections in the laminate web are located on and emanate from the outer surface of the web. The hollow projections have open ends which are located towards the inner surface of the web and may be covered by the second surface of the support layer or web or the inner surface of the projection web, depending upon the amount of fiber that has been used from the projection web to form the projections. The projections are surrounded by land areas, which are also formed from the outer surface of the projection web, though the thickness of the land areas is comprised of both the projection web and the support layer. This land area may be relatively flat and planar or it may have topographical variability built into it. For example, the land areas may be provided with depressions which extend all or part way into the projection web and/or the support layer. In addition, the land areas may be subjected to embossing which can impart surface texture and other functional attributes to the land area. Still further, the land areas may be provided with apertures which extend through the laminate so as to further facilitate the movement of fluids (such as the foam exuded by the core layer) into and through the laminate.

A particularly preferred second outer member 18 is illustrated in FIG. 3. The fluid entangled web 23 comprises a plurality of projections 32. Interposed between projections 32 are land areas 34 lying in a first plane. Together the projections 32 and the land areas 34 form the second side 26 of the article 10. Generally the projections extend outwardly and away from the first plane and terminate at distal ends to define a second plane. The height of the projections may vary, but generally projections are of similar height and define a second plane lying above the first plane.

Generally the material forming the second outer member provides the second side with a coefficient of friction less than the first side. For example, in certain embodiments, the second side has a coefficient of friction less than 0.50 and more preferably less than about 0.40 and still more preferably less than about 0.35, such as from about 0.20 to 0.50 and more preferably from about 0.30 to about 0.40. In other embodiments, in addition to having modest coefficient of friction the second outer member may be relatively smooth, such as a surface smoothness less than about 0.025 and more preferably less than about 0.020, such as from about 0.005 to about 0.025 and more preferably from about 0.075 to about 0.020. In certain preferred embodiments the second outer layer comprises a fluid entangled web comprising a plurality of hollow projections having an average height from about 0.75 to about 1.5 mm, a coefficient of friction from about 0.30 to about 0.40 and a surface smoothness from about 0.075 to about 0.020.

In addition to the first and second outer members the article generally comprises one or more inner layers, such as a core member, to provide additional and/or enhanced functions. Thus, the article can be used to clean a user's skin, and particularly their face, by wetting the article and then rubbing one or both of the first and second sides against the same to achieve the desired level and type of cleaning.

By way of example and in reference to FIG. 4, the cleansing article 10 may optionally include a core member 16 to add to or enhance the functionality of the cleansing article 10. In one aspect the core member 16 may be located between the first outer member 14 and second outer member 18. The core member 16 can comprise one or more different materials depending on the desired properties of the cleansing article 10. In one aspect, the core member 16 may provide or enhance the ability of the cleansing article 10 to generate foam such as through the use of a resiliently-deformable porous material. In this regard, the compression and expansion of the porous material works in combination with existing and/or applied cleanser to generate numerous bubbles and create a rich foam or lather. Highly porous, low density materials that are resiliently-deformable are well suited to providing such a function; suitable materials include, but are not limited to, through-air bonded nonwoven fabrics, porous or open cell foams, compressed viscose or cellulose, and so forth. By way of non-limiting example, materials capable of providing such a benefit include those described in U.S. Pat. Nos. 4,068,036, 5,985,434 and 7,358,282.

In a further aspect, the core member may be employed to improve the ease of handling the cleansing article such as by providing additional stability or bending stiffness to the cleansing article such that the article does not readily bend or fold onto itself under its own weight or the weight of any applied water or cleansers. The bending stiffness or stability of the article or core member can be increased by the use or addition of one or more supporting layers such as a scrim reinforcing material or by increasing the density or the degree of cross-linking or interstitial bonding within the materials comprising the core member 16. In this regard, the aforementioned materials suitable for foam generation may also be provided with relatively higher degrees of bonding or cross-linking in order to obtain the desired degree of bending stiffness and resiliency. The size and location of the core member 16 will vary with the selected material and function. In many embodiments, it will be desirable for the core member to be centrally located within the article and to have a size that is smaller than that of the article itself such that the core member does not extend to the edge or form a part of any edge seal.

In yet a further aspect, the core member may be utilized to provide a visual or tactile cue to the user that the article is sufficiently wetted for use. By way of example, the core member may comprise one or more materials that significantly expand upon wetting such that the user can easily see or feel an increase in the volume of the article and thereby understand when the article if sufficiently wet and ready for use. In this regard, the core member may comprise a sealed packet or pouch containing highly water-swellable materials such as, for example, “superabsorbent” materials. Superabsorbent materials are well known and widely used in absorbent personal care articles such as diapers and other incontinence garments; non-limiting examples of which include alkali metal salts of polyacrylic acids, polyacrylamides, polyvinyl alcohol, ethylene maleic anhydride copolymers, polyvinyl ethers, hydroxypropyl cellulose, polyacrylates, modified starch such as hydrolyzed acrylonitrile grafted starch, and so forth. The swellable or superabsorbent materials may be in any form suitable for use in the article, including, particles, fibers, flakes, spheres, and the like. The swellable material may be sealed within or between one or more layers of liquid permeable materials such as, for example, sheets of cellulosic tissue or meltblown. By way of non-limiting example, suitable superabsorbent materials and methods of incorporating the same into materials and/or pouches are described in U.S. Pat. Nos. 4,646,510, 5,458,592 and 6,162,961, the expandable or swellable material may comprise an absorbent, swellable foam.

In certain embodiments the cleansing article may include multiple core members so as to improve and/or provide multiple distinct functions of the same. By way of example, the cleansing article may include a first core member comprising a resiliently-deformable porous layer capable of improving foam generation and handleability. In addition, the cleansing article may further include a second core member comprising a porous layer impregnated with a cleaning formulation. Thus, after wetting the article, a user's squeezing and releasing of the article causes the cleaning formulation to transfer to outer members and for air to be draw into and pushed throughout the layers of the article thereby aiding in the development of a rich foamy lather.

In a further aspect, one or more layers of the article may include one or more cleaning or exfoliating agents to assist with the desired function of the article. For example, the first or second outer member, or the core, may be impregnated with or have applied thereto a cleaning formulation. Skin cleaning formulations are well-known in the art and may include one or more of the following ingredients: cleansing and/or foaming (lathering) surfactants, detergents, builders, foam stabilizers, astringents, essential oils, plant extracts, humectants, moisturizing agents, buffering agents, chelating agents, anti-microbial agents, pigments, colorants, fragrances, and so forth. Foam generating surfactants, i.e. lathering surfactants, are widely known and used and are particularly well suited for use in cleansing formulations included in the cleansing article of the present invention. By way of example, suitable foam generating surfactants include, but are not limited to, glucosides (e.g. alkyl glucosides, alkyl polyglucosides, etc.), betaines (e.g. cetyl betaine, cetyl dimethyl betaine, cocamidopropyl betaine, lauryl dimethyl carboxymethyl betaine, etc.), alkyl and alkyl ether sulfates (e.g. sodium lauryl sulfate sodium, sodium laureth sulfate, cetyl sulfate, etc.), alkoxylated fatty acid esters, sultaines (e.g. cocamidopropyl hydroxysultaine, etc.), amine oxides (e.g. lauramine oxide, cocoamine oxide, etc.), alkyl isethionates (e.g. sodium cocoyl isethionate, sodium lauroyl isethionate, etc.), and so forth. Further, non-limiting examples of suitable cleaning formulations are described in U.S. Pat. No. 6,806,213 and US Publication Nos. US2003/207632 and US2005/136531. Desirably, one or more of the interior layers, such as the first outer member or a core layer, includes an effective amount of a lathering surfactant to enable the formation of a rich lather upon repeatedly pressing and releasing the wet article. As but one specific example, the cleaning formulation may include a combination of the following ingredients: decyl glucoside, glycerin, cocamidopropyl betaine, PEG-7 glyceryl cocoate, tocopheryl acetate, malic acid, and a cosmetically acceptable preservative.

The article, and cleaning formulation, may be provided in either a moist or dry form as desired. By way of non-limiting example, cleaning formulations may be applied to a core layer by dipping, spraying, printing (e.g. flexographic, rotogravure, offset, etc.), gravure coating, flexographic coating, slot coating, foam application, and so forth. Often it will be desirable to apply the cleaning formulation in aqueous form and thereafter remove excess water by hot air drying or other methods in order to achieve either a dry product or a moist product with higher percentages of functional ingredients. In alternative embodiments, it is noted that a cleansing formulation may be separately and/or additionally impregnated in or applied to one or more of the other layers including the first outer member or the second outer member. In certain embodiments, it will be desirable for the article to comprise, based upon its dry weight, between about 1 and 500 percent by weight of a cleaning formulation and/or a lathering surfactant. In still further embodiments, it will be desirable for the article to comprise between about 1 and about 250 percent, and still more desirably between about 5 and about 100 percent, of a cleaning formulation and/or lathering surfactant (based upon the dry weight of the article).

In a further aspect, any one or more layers in the cleansing article may optionally include one or more additives or topical agents in order to modify or improve its inherent hydrophilic and/or hydrophobic character. Often it will be desirable to increase the wettability or hydrophilic characters of a layer such as, for example, by the application or inclusion of wetting agents and/or surfactants. As a further option, one or more layers may include pigments, opacifying agents, softening agents, particulates, fragrances and so forth as desired to impart or improve one or more physical or aesthetic attributes. The materials comprising the various layers may also optionally be physically treated as desired to enhance or improve additional characteristics such as, for example, hand (feel), appearance, durability, and so forth. In this regard, examples of commonly employed treatments include, but are not limited to, embossing, stretching, creping, printing, needling and so forth.

The various layers forming the article may be combined with one another to form a single integral article. The various layers may be joined by one or more means known in the art. By way of example, the first and second outer members may be joined to one another through the use of adhesive, thermal bonding, mechanical crimping, needle stitching, and so forth. In addition, it is noted that other adjacent layers may be further joined to the first and/or second outer member through the use of similar methods to achieve increased article integrity as desired. For example, with reference to FIG. 4, the first and second members 14, 18 may be joined to one another near the periphery 20 of article 10 by embossments 22.

As noted previously, the first and second sides 24, 26 preferably have different textures, which are generally provided by the use of different materials to form the two outer layers 14, 18. For example, with reference to the embodiment illustrated in FIG. 4, the first outer member 14 comprises a nonwoven web having a plurality of polymeric protuberances 30 disposed thereon and the second outer member 18 comprises a fluid-entangled laminate web having a plurality of projections 32 formed from the laminate web. The construction of the first outer member 14, including the nonwoven web and the polymeric material used to form the protuberances 30, may be designed such that the first side 24 has a coefficient of friction greater than 0.50, more preferably greater than about 0.55, such as from about 0.55 to about 1.00. Conversely the fluid-entangled laminate web forming the second outer member 18 may be constructed such that the second side 26 has a coefficient of friction less than 0.50 and more preferably less than about 0.45, such as from about 0.20 to 0.50.

Thus, in certain embodiments the first and second sides 24, 26 have different coefficients of friction where the coefficient of friction of the first side 24 is greater than the coefficient of friction of the second side 26, such as at least about 10 percent greater, and more preferably at least about 30 percent greater and still more preferably at least about 75 percent greater, such as from about 10 to about 125 percent greater and more preferably from about 30 to about 100 percent greater. For example, the first side 24 may have a coefficient of friction greater than about 0.55 and the second side 26 may have a coefficient of friction less than about 0.45.

In addition to providing the first and the second sides 24, 26 of the article 10 with different degrees of texture, the materials used to form the first and second members 14,18 may be selected such that the first and the second sides 24, 26 have differing degrees of permeability. For example, in one embodiment, the first outer member 14 has a permeability of 500 cfm or greater, such as from 500 to about 700 cfm and more preferably from about 500 to about 600 cfm and still more preferably from about 525 to about 575 cfm. Conversely, the second outer member has a permeability less than 500 cfm, such as from about 300 to 500 cfm and more preferably from about 400 to about 475 cfm. In this manner the permeability of the first and the second sides 24, 26 differs such that when the core member 16 is designed to generate foam such as through the use of a resiliently-deformable porous material the foam is transmitted through the first and the second sides 24, 26 at differing degrees. As such, the article may have sides with differing degrees of texture and foaming to provide the user with two distinct cleansing experiences.

Test Methods Air Permeability

Air permeability, which expresses the permeability of a material in terms of cubic feet per minute of air through a square foot of area of a surface of the material at a pressure drop of 100 Pa, was determined in accordance with ISO 9237:1995. The measurement was taken using a TEXTEST FX 3300 (TEXTEST AG, Switzerland) fitted with a 20 cm² head at a test pressure of 100 Pa.

Surface Properties

The surface properties of samples were measured on KES Surface Tester (Model KE-SE, Kato Tech Co., Ltd., Kyoto, Japan). For each sample the coefficient of friction and/or surface smoothness was measured according to the Kawabata Test Procedures with samples tested along MD and CD and on both sides for five repeats with a sample size of 10 cm×10 cm. Care was taken to avoid folding, wrinkling, stressing, or otherwise handling the samples in a way that would deform the sample. Samples were tested using a multi-wire probe of 10 mm×10 mm consisting of 20 piano wires of 0.5 mm in diameter each with a contact force of 25 grams. The test speed was set at 1 mm/s. The sensor was set at “H” and FRIC was set at “DT”. The data was acquired using KES-FB System Measurement Program KES-FB System Ver 7.09 E for Win98/2000/XP (commercially available from Kato Tech Co., Ltd., Kyoto, Japan). The selection in the program was “KES-SE Friction Measurement.”

KES Surface Tester determined the coefficient of friction (MIU) and mean deviation of MIU (MMD), where higher values of MIU indicate more drag on the sample surface and higher values of MMD indicate more variation or less uniformity on the sample surface.

The values MIU and MMD are defined by:

MIU(μ)=1/X∫ ₀ ^(x) μdx

MMD=1/X∫ ₀ ^(x) |μ−μ|dx

where μ=friction force divided by compression force μ=mean value of μ x=displacement of the probe on the surface of specimen, cm X=maximum travel used in the calculation, 2 cm The top surface of each product sample was tested five times and resulting MMD and MIU values averaged and reported as coefficient of friction (COF) and surface smoothness.

Image Analysis

Image analysis of samples was carried out using a Leica Microsystems QWIN Pro Image Analysis system (Version 3.5.1, commercially available from Leica Microsystems, Heerbrugg, Switzerland) under the optical axis of a 20 mm Nikon AF lens with an f-stop setting of 4. The Nikon lens was attached to the Leica DFC 310 FX camera using a c-mount adaptor. Two-dimensional coverage, spacing, density and sizing data were acquired via the QUIPS algorithm “Coverage, Size & Spacing Distribution—1.” The optical configuration is described in the algorithm.

Three-dimensional surface maps and height profiles were acquired using a Leica 3D stereo microscope with Mountains surface topography software. Z-height image slice focusing was performed at 30× magnification, while image slices (8) were acquired at 7.8× magnification.

EXAMPLES

Several different exfoliating products were prepared to evaluate the effect of basesheet, printing material and patterns on surface properties and exfoliation. The articles comprised three layers—a first outer member comprising a nonwoven web screen printed with an expandable ink, a foam core and a second outer member comprising a fluid-entangled nonwoven web having a plurality of hollow projections (commercially available from Textor Technologies, Victoria, Australia). The first outer member comprised a bonded carded web formed from bi-component fibers (polyethylene and polypropylene) having a basis weight of about 57 grams per square meter (gsm) and a caliper of about 1.27 mm. (commercially available from Precision Customer Coating, Totowa, N.J.). The desired patterns were printed on the basesheets by screen printing a paste that expands under heating by virtue of a puffing agent contained therein. The paste used to produce the inventive samples is marketed as Altoma Puff Paste (Bolger & O'Hearn, Inc., Fall River, Mass.). The webs were printed using conventional screen printing technology using a printing screen imparted with a pattern. The screen pattern consisted of a random pattern of dots and a non-random pattern circles formed from twelve dots. Both patterns comprised dots having a diameter of 0.6 mm. After printing webs were cured by heating in an oven at about 310° F. After curing the printed web was laminated with a core and the second outer member and embossed about its periphery to form a textured cleansing article. Products were subjected to analysis as described in the Test Methods section above, the results of which are summarized in Table 1, below.

TABLE 1 Pattern Dot First Side Second Side Trail Diameter Coefficient First Side Coefficient Second Side Code Pattern (mm) of Friction Smoothness of Friction Smoothness 1 Random 0.6 0.556 0.038 0.388 0.0127 2 Non-Random Circles 0.6 0.554 0.038 0.378 0.0075

While the inventive textured cleansing articles have been described in detail with respect to the specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these embodiments. Accordingly, the scope of the present invention should be assessed as that of the appended claims and any equivalents thereto and the following embodiments:

In a first embodiment the present invention provides a cleansing article comprising: a first member comprising a nonwoven web having a first and a second side and a plurality of polymeric protuberances disposed on the first side thereof, the first side forming the first outer surface of the cleansing article; a second member comprising a nonwoven web having a first and a second side, the first side having a plurality of projections substantially surrounded by a landing, the land areas lying in a first plane and the projections terminating at distal ends lying in a second plane, the first and second planes spaced apart a vertical distance from about 0.5 to about 1.5 mm, wherein the first side forms the second outer surface of the cleansing article; and a core.

In a second embodiment the present invention provides the cleansing article of the first embodiment wherein the first outer surface of the cleansing article has a coefficient of friction greater than the second outer surface of the cleansing article.

In a third embodiment the present invention provides the cleansing article of the first or second embodiments wherein the coefficient of friction of the first outer surface of the cleansing article is greater than 0.50 and the coefficient of friction of the second outer surface of the cleansing article is less than 0.50.

In a fourth embodiment the present invention provides the cleansing article of any one of the first through third embodiments wherein the first member has a permeability greater than the second member.

In a fifth embodiment the present invention provides the cleansing article of any one of the first through fourth embodiments wherein the first member has a permeability of 500 cfm or greater and the second member has a permeability less than 500 cfm.

In a sixth embodiment the present invention provides the cleansing article of any one of the first through fifth embodiments wherein the protuberances are non-hollow and the projections are hollow.

In a seventh embodiment the present invention provides the cleansing article of any one of the first through sixth embodiments wherein the protuberances have a hardness from about 65 to about 100.

In an eighth embodiment the present invention provides the cleansing article of any one of the first through seventh embodiments wherein the protuberances are disposed on the first side at a density greater than about 5 protuberances per square centimeter.

In a ninth embodiment the present invention provides the cleansing article of any one of the first through eighth embodiments wherein the protuberances are disposed on the first side in a non-random pattern and wherein the density of protuberances is from about 100,000 to about 200,000 protuberances per square meter.

In a tenth embodiment the present invention provides the cleansing article of any one of the first through ninth embodiments wherein the core is a porous open cell foam and further comprises a cleansing formulation.

In an eleventh embodiment the present invention provides the cleansing article of any one of the first through tenth embodiments wherein the second member comprises a fluid-entangled laminate web having an outer and an inner surface, the outer surface of the web having a plurality of hollow projections.

In a twelfth embodiment the present invention provides the cleansing article of any one of the first through eleventh embodiments wherein the second side has a coefficient of friction from about 0.30 to about 0.40 and a surface smoothness less than about 0.025.

In an thirteenth embodiment the present invention provides the cleansing article of any one of the first through twelfth embodiments wherein the second outer layer comprises a fluid entangled web comprising a plurality of hollow projections having an average height from about 0.75 to about 1.5 mm, a coefficient of friction 0.30 to about 0.40 and a surface smoothness from about 0.075 to about 0.020.

In a fourteenth embodiment the present invention provides the cleansing article of any one of the first through thirteenth embodiments wherein the plurality of polymeric protuberances are printed in a non-random pattern having a protuberance density from about 100,000 to about 200,000 protuberances per square meter and an average height from about 250 to about 1,000 μm. 

1. A cleansing article comprising: a) a first member comprising a nonwoven web having a first and a second side and a plurality of hollow protuberances disposed on the first side thereof, the first side forming the first outer surface of the cleansing article; b) a second member comprising a nonwoven web having a first and a second side, the first side having a plurality of non-hollow projections substantially surrounded by a landing, the land areas lying in a first plane and the projections terminating at distal ends lying in a second plane, the first and second planes spaced apart a vertical distance from about 0.5 to about 1.5 mm, wherein the first side forms the second outer surface of the cleansing article; and c) a core; wherein the first outer surface of the cleansing article has a coefficient of friction greater than the second outer surface of the cleansing article.
 2. The cleansing article of claim 1 wherein the coefficient of friction of the first outer surface of the cleansing article is greater than 0.50 and the coefficient of friction of the second outer surface of the cleansing article is less than 0.50.
 3. The cleansing article of claim 1 wherein the plurality of protuberances have an average height greater than about 250 μm and the first outer surface of the cleansing article has a coefficient of friction from about 0.55 to about 0.75.
 4. The cleansing article of claim 1 wherein the first member has a permeability greater than the second member.
 5. The cleansing article of claim 4 wherein the first member has a permeability of 500 cfm or greater and the second member has a permeability less than 500 cfm.
 6. (canceled)
 7. A textured cleansing article comprising: a) a first member comprising a nonwoven web having a first and a second side, the web having a permeability of 500 cfm or greater and the first side having a coefficient of friction greater than 0.5; b) a second member comprising a fluid-entangled laminate web having an outer and an inner surface, the outer surface of the web having a plurality of hollow projections having an average height from about 0.5 to about 2.0 mm and a first and a second side, the web having a permeability less than 500 cfm and the first side having a coefficient of friction less than 0.5; and c) a porous open cell foam core comprising a cleansing formulation.
 8. The textured cleansing article of claim 7 further comprising a plurality of protuberances disposed on the first side, the protuberances having an average height greater than about 250 μm.
 9. The textured cleansing article of claim 8 wherein the protuberances are polymeric and have a hardness from about 65 to about
 100. 10. The textured cleansing article of claim 8 wherein the protuberances are disposed on the first side at a density from about 100,000 to about 200,000 protuberances/m².
 11. The textured cleansing article of claim 8 wherein the protuberances are disposed on the first side in a non-random pattern, the protuberances having an average height from about 250 to about 1,000 μm.
 12. (canceled)
 13. (canceled)
 14. A textured cleansing article comprising: a) a first member comprising a nonwoven web having an outer and an inner surface, a plurality of non-hollow protuberances disposed on the outer surface, the first member having a permeability greater than 500 cfm and a coefficient of friction greater than 0.50; b) a second member comprising a fluid-entangled laminate web having an outer and an inner surface, the outer surface of the web having a plurality of hollow projections, the second member having a permeability less than 500 cfm and a coefficient of friction less than 0.50; and c) a core disposed between the first and the second members.
 15. The textured cleansing article of claim 14 further comprising a plurality of protuberances disposed on the first side and the first side having a coefficient of friction from 0.50 to about 0.75.
 16. The textured cleansing article of claim 15 wherein the protuberances are polymeric and have an average height from about 250 to about 1,000 μm.
 17. The textured cleansing article of claim 15 wherein the protuberances are disposed on the first side at a density from about 100,000 to about 200,000 protuberances/m².
 18. The textured cleansing article of claim 15 wherein the protuberances are disposed on the first side in a non-random pattern and a density from about 100,000 to about 200,000 protuberances/m², the first side having a coefficient of friction from about 0.55 to about 0.65.
 19. The textured cleansing article of claim 14 wherein the core is a porous open cell foam and further comprises a cleansing formulation.
 20. The textured cleansing article of claim 14 wherein the second member comprises a fluid-entangled laminate web having an outer and an inner surface, the outer surface of the web having a plurality of hollow projections. 